Support structure for pleated filter media and methods

ABSTRACT

A support structure for an interior volume of a construction of pleated media is operably oriented in the interior volume and structurally supports the media. The support structure can pass directly through an innermost 60% of the interior volume. It can have a void volume not more than 80%. It can be inner liner-free and extend in a non-curved path. It can include a first sheet and second sheet of porous material. At least a first brace construction secures the first sheet and second sheet together and in spaced apart, opposing relation. The support structure can include a pleated construction having pleats extending in a direction non-parallel and angled to the direction of pleats of the pleated filter media. The support structure can be molded spacers.

This application claims priority to provisional application 61/895,197,filed Oct. 24, 2013, incorporated by reference herein.

TECHNICAL FILED

This disclosure concerns a support structure for a tubular constructionof pleated media. In particular, this disclosure concerns a poroussupport structure for a filter element having pleated media, methods ofconstruction, and methods of use.

BACKGROUND

Filter elements of pleated media are often arranged in a tubularconstruction. By the word “tubular”, it is meant a closed loop, whichcan be round, non-round, oval, elliptical, etc. The filter elements canbe used in a variety of applications such as cleaning the air intake forcompressors, or filtering the air in dust collectors, just to name acouple of examples. In many cases, the fluid to be filtered flows fromthe exterior, through the pleats, and into the open interior volume ofthe tubular construction. In many situations, it is desirable to supportthe pleated media from within the interior volume of the filter elementin order to prevent the pleats from collapsing against themselves in theinterior volume. When the tubular construction is oval or elliptical,the problem with having the pleats collapse against themselves is evenmore of an issue because of the geometry of the cross-sectional shape ofthe media construction.

One typical approach to supporting filter media within the interior ofthe filter includes using an inner filter liner. The inner filter lineris often made from metal and is porous or porous to allow fluid flowtherethrough. There have been uses of non-metal as inner liners, aswell.

In some environments which these filters operate, the environment isnoisy due to operation of machinery, such as a generator, blower, orengine. Some filter constructions generate excessive noise due to airvelocity, filter configuration, etc.

Improvements in media support and/or in ways to reduce noise aredesirable.

SUMMARY

In accordance with principles of this disclosure, a filter element isprovided. The filter element includes a construction of pleated filtermedia defining an interior volume. The first and second opposite endcaps are secured to opposite ends of the filter media. A supportstructure supports the filter media and is operably oriented in theinterior volume.

The support structure can bridge or extend between opposing faces of thepleated filter media and pass directly through an innermost 60% of theinterior volume.

The support structure can have a void volume of no more than 80%.

The support structure can be inner-liner free.

The support structure can extend in a non-curved path between opposingfaces of the pleated media.

The support structure can include a pleated construction having pleatsextending in a direction non-parallel and angled relative to a directionof pleats of the pleated filter media in which it is operably orientedwithin the interior volume 54.

In one or more example embodiments, the pleated construction extends atan angle 80-100 degrees relative to the direction of pleats of thepleated filter media.

In one or more example embodiments, the pleats of the pleatedconstruction extend about perpendicular relative to the direction ofpleats of the pleated filter media.

In example embodiments, the pleated construction can comprise asemi-rigid pleated screen.

The support structure can include at least a first wall of porousmaterial oriented against the filter media in the interior volume. Thesupport structure can include at least a second wall of porous material,spaced from and opposing the first wall, and oriented against the filtermedia in the interior volume. The first wall and second wall can besecured together in spaced apart, opposing relation.

The forces are equal and opposite on the first and second walls of thespacer.

In some aspects, the support structure can extend a complete lengthbetween the first and second end caps. Alternatively, the supportstructure can extend less than a complete length between the first andsecond end caps.

In some aspects, the support structure further includes at least a thirdwall of porous material. The third wall is between, and spaced from, thefirst wall and second wall and is secured to the first wall and secondwall.

In some aspects, the first wall is secured to the third wall with acorrugated material, and the third wall is secured to the second wallwith a corrugated material.

The support structure may comprise a plurality of molded spacers.

In one or more embodiments, the molded spacers can be spaced from eachother.

In one or more embodiments, the molded spacers can be angled at anon-zero and non-perpendicular angle relative to the direction of pleatsof the pleated media.

In some embodiments, the molded spacers can be angled at an angle 30-150degrees relative to the direction of pleats of the pleated filter media.

In some examples, the molded spacers can be angled at an angle 100-140degrees relative to the direction of pleats of the pleated media.

The spacers may comprise molded polyurethane.

In one or more embodiments, there are at least two spacers having adifferent length.

In one or more embodiments, each spacer has a first wall secured to aninterior face of the pleated media, and a second wall opposite the firstwall secured to an opposite interior face of the pleated media.

In one or more example embodiments, the second wall of the spacerincludes at least one scallop shape.

In some example aspects, the support structure is secured to at leastthe second end cap.

In example aspects, the pleated filter media is non-round and could berectangular, oval, or elliptical.

In example aspects, the support structure has a rectangularcross-section perimeter shape.

In accordance with principles of this disclosure, a method of filteringis provided. The method includes providing a filter element having atubular construction of pleated filter media defining an open interiorvolume and first and second opposite end caps secured to opposite endsof the filter media. The method includes directing fluid to flow throughthe pleated media and into the interior volume. While the fluid isflowing through the pleated filter media, the method includes supportingthe filter media to prevent the filter media from collapsing together byusing a support structure oriented in the interior volume.

In accordance with principles of this disclosure, a support structurefor an interior volume of a tubular construction of pleated media isprovided. The support structure includes at least a first sheet andsecond sheet of material. Each of the first sheet and second sheet isporous to allow fluid flow therethrough. At least a first braceconstruction of material secures the first sheet and second sheettogether and in spaced apart, opposing relation. The first braceconstruction is porous to allow fluid flow therethrough.

In some aspects, the first brace construction comprises a firstcorrugated sheet.

In some aspects, there is also a third sheet of material that is porousto allow fluid flow therethough. At least a second brace construction ofmaterial secures the third sheet to the second sheet in spaced, opposingrelation and on an opposite side of the second sheet as the first sheet.The second brace construction is porous to allow fluid to flowtherethrough.

In example aspects, the support structure comprises cellulose.

It is noted that not all the specific features described herein need tobe incorporated in an arrangement for the arrangement to have someselected advantage according to the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a support structure,constructed in accordance with principles of this disclosure;

FIG. 2 is an enlarged view of section A-A of FIG. 1;

FIG. 3 is a perspective view of the support structure of FIG. 1 operablyassembled within a tubular construction of pleated media, constructed inaccordance with principles of this disclosure;

FIG. 4 is an enlarged view of section B-B of FIG. 3;

FIG. 5 is a front view of one example filter element having a supportstructure constructed in accordance with principles of this disclosure;

FIG. 6 is an enlarged view of an upper portion of the filter element ofFIG. 5;

FIG. 7 is a top view of the filter element of FIGS. 5 and 6, in whichthe support structure can be seen operably oriented within the openfilter interior;

FIG. 8 is a perspective view of the support structure of FIG. 1 operablyassembled within a tubular construction of pleated media, constructed inaccordance with principles of this disclosure;

FIG. 9 is an enlarged view of section C-C of FIG. 8;

FIG. 10 is an exploded perspective view of another embodiment of asupport structure for a tubular construction of pleated media,constructed in accordance with principles of this disclosure;

FIG. 11 is an enlarged view of section D-D of FIG. 10;

FIG. 12 is a view analogous to FIG. 7, but the filter element having thesupport structure of FIG. 10;

FIG. 13 is a schematic, perspective view of another embodiment of asupport structure for a tubular construction of pleated media,constructed in accordance with principles of this disclosure;

FIG. 14 is a schematic side elevational view of the embodiment of FIG.13;

FIG. 15 is a schematic, top perspective view of the embodiment of FIG.13;

FIG. 16 is a schematic, top plan view of the embodiment of FIG. 13;

FIG. 17 is a schematic, perspective view of an embodiment of a spacerused as a support structure in the embodiment of FIGS. 13-16;

FIG. 18 is a side view of the spacer of FIG. 17; and

FIG. 19 is a schematic cross-sectional view of another embodiment of asupport structure for a tubular construction of pleated media,constructed in accordance with principles of this disclosure.

DETAILED DESCRIPTION

One of the problems with pleated filter elements, and in particular,tubular pleated elements, is that they are more easily crushed bypressure created during operation of the filter. By placing a porouscore in the open filter interior, rigidity is added to the filterelement. This will make the element more reliable, than in constructionswithout such support. When the support structure is made of a cellulosematerial, the element is more environmentally friendly. This alsocontributes to making the filter element lighter and more easilyserviced, than in constructions that have a metal inner liner. Inaddition, in environments that are noisy, the support structure can beconstructed to dampen sound. Further advantages can be achieved when theelement is made rectangular in shape, in which three dimensional spaceis limited. Oval shaped elements can also have advantages in fitting inlimited space. Further, by making the filter element without the use ofany metal of steel, cost to manufacture the element will be reduced.

First, attention is directed to FIGS. 3, 4, 8, and 9, which illustrateone example support structure 10 operably oriented in an interior volumeof a construction of pleated media 50. The pleated media 50 can betubular shape 52, defining an interior volume 54 (FIGS. 4 and 9). Inthese examples, the support structure 10 is within the interior volume54. The tubular shape 52 can be any shape forming a closed loop, such asround, non-round, oval, rectangular, or elliptical, for example. In theexample shown in FIG. 3, the tubular shape 52 includes an oval shape 56.In the example shown in FIG. 8, the tubular shape 52 is rectangular.

The pleated media 50 has a plurality of pleats 58. The pleats 58, in theembodiment shown, have outer pleat tips 60 and inner pleat tips 62. Theouter pleat tips 60 are along the exterior of the pleated media 50. Theinner pleat tips 62 are along the interior volume 54. The pleated media50, when in the tubular shape, has first and second opposing faces 64,66 (FIGS. 4 and 9), which generally correspond to the inner pleat tips62.

The pleated media 50 can be part of a filter element 70 (FIGS. 5-7).Many different types of elements 70 are possible. In the element 70illustrated in FIG. 5, the element 70 includes the tubular constructionof pleated media 50. The tubular construction defines interior volume 54(FIG. 7). More details on the example filter element 70 are discussedbelow.

The support structure 10 supports the pleated filter media 50. By“supports”, it is generally meant a structural mechanism to resistopposing forces. The support structure 10 prevents pleat collapse andcrushing of the element together through the interior. By “pleatcollapse,” it is meant that the support structure 10 prevents individualpleats from collapsing inwardly towards the center (interior volume 54)of the element 70 and the element 70 crushing together through theinterior.

The support structure 10 is operably oriented in the interior volume 54of the pleated media 50. In many examples, the support structure 10bridges between the first opposing interior face 64 to the secondopposing interior face 66. For example, the support structure 10 extendsfrom the first opposing interior face 64 to the second opposing interiorface 66 to structurally support the pleated media 50.

In providing support to the pleated media 50, the support structure 10passes directly through an innermost 60% region 92 (dashed line box inFIG. 7) of the interior volume 54. That is, when viewing the tubularpleated media 50 in plan (top view, such as FIG. 7), such that theinterior volume is shown in the center of the tubular pleated media, theinnermost 60% region 92 includes the area proximate the center of theinterior volume 54 and the area emanating from the center in thedirection toward the opposing interior faces 64, 66.

In many implementations, the support structure 10 passes directlythrough an innermost 40% region 94 (dashed line box inside of box 92) inFIG. 7 of the interior volume 54, and frequently through an innermost20% region 96 (dashed line box inside of box 94) of the interior volume54. In the example shown in FIG. 7, the support structure 10 passesdirectly through the innermost 60% region 92, and the innermost 40%region 94, and through the innermost 20% region 96. It should beunderstood that in some examples, a support structure can pass throughthe innermost 60% region 92 and not pass through either of both of theregions 94, 96.

The support structure 10 is sturdy enough to structurally support thepleated media 50, yet light enough to not add excessive weight to theelement 70. The support structure 10, further, does not contributesignificantly to restriction (pressure drop) across the element 70. Toachieve these advantages, it has been found that the support structure10 will typically have a void volume not greater than 80%. “Void volume”is the amount of open space, or space not occupied by material. In manycases, advantages are achieved if the void volume is not greater than60%.

The support structure 10 functions to structurally support the pleatedmedia 50 while being operably oriented in the interior volume 54, andthe support structure 10 is not an inner liner for the pleated media 50.Thus, the support structure 10 structurally supports the pleated media50 in the absence of an inner liner. As such, the support structure 10is inner liner-free. In some implementations, the filter element 70 isinner liner-free.

In one or more embodiments, the filter element 70 may include anadditional porous structure in the interior volume 54, lining the mediainterior. The porous structure lining the media interior will typicallynot be sufficiently strong to function as a support to the pleated media50. The porous structure can be flimsy material, such as netting, etc.

The support structure 10, in some implementations, extends in anon-curved path from the first opposing interior face 64 to the secondopposing interior face 66 to structurally support the pleated media 50.

The filter element 70 includes means for supporting the pleated filtermedia 50. The means for supporting includes the support structure 10,which is between and against opposing faces 64, 66 of the pleated filtermedia 50.

FIGS. 1 and 2 illustrate a first example embodiment of a supportstructure 10. The support structure 10 can be used in an interior volumeof a tubular construction of pleated media. As mentioned previously, bythe term “tubular”, it is meant any shape that forms a closed loop,which can be round, non-round, oval, elliptical, etc.

The support structure 10 includes at least a first member or sheet 12 ofa material. In some examples, the material can be non-metal. The firstsheet 12 is porous with a plurality of openings or holes 14 to allowfluid flow therethrough. In the example shown, although the porous holes14 are illustrated as circular, it should be understood that any shapeof hole can be used, provided that the fluid to be filtered can bepassed through it without introducing excess restriction.

The support structure 10 includes at least a second member or sheet 16of material. In some examples, the material can be non-metal. The secondsheet 16 is porous in that it includes a plurality of openings or holes18. Again, the openings 18 are shown to be circular, but can be anyshape.

The first sheet 12 and second sheet 16 may be generally flat and planar,and absent of folds. In the example illustrated in FIG. 1, the firstsheet 12 and second sheet 16 are generally rectangular in shape. Othershapes can be used.

The first sheet 12 and second sheet 16 are secured together and spacedapart in opposing relation (e.g., facing each other). The first sheet 12and second sheet 16 can be secured together by using a first braceconstruction 20 (FIG. 2).

The first brace construction 20 is a material that will operably holdthe first sheet 12 and second sheet 16 in a spaced-apart relation, butsecure them together. In many examples, the first brace construction 20is made from a non-metal material. The first brace construction 20 isporous by including a plurality of openings or holes 22.

As mentioned above, the first brace construction 20 can be any type ofstructure that will secure the first sheet 12 and second sheet 16together, but hold them in a spaced apart relationship, and allow forthe flow of fluid therethrough. In the particular example illustrated inFIGS. 1 and 2, the first brace construction 20 is a flute or firstcorrugated member or sheet 24.

The corrugated sheet 24 includes a member having a plurality ofalternating ridges 26 and troughs 28. The exterior surface of the ridges26 and troughs 28 are used for attaching or securing the sheets 12, 16together. The sheets 12, 16 can be secured together using a variety oftechniques such as glue or adhesive.

The support structure 10 can further include at least a third member orsheet 30. The third sheet 30, in many examples, can be of a non-metalmaterial. The third sheet 30 will be porous with a plurality of openingsor holes 32 to allow for fluid flow therethrough.

In the embodiment shown, the third sheet 30 is spaced apart from andopposing the second sheet 16. In this way, the second sheet 16 islocated between the first sheet 12 and third sheet 30.

The third sheet 30 is secured to the second sheet 16. A second braceconstruction 34 can be used to secure the third sheet 30 and secondsheet 16 together and in spaced apart, opposing relation.

A variety of implementations for the second brace construction 34 arepossible. In the embodiment illustrated, the second brace construction34 is a flute or second corrugated member or sheet 36.

As with the first corrugated sheet 24, the second corrugated sheet 36includes a member having a plurality of alternating ridges 38 andtroughs 40. Along the exterior of each ridge 38 and trough 40, therespective second sheet 16 and third sheet 30 can be attached to thecorrugated construction 36. This attachment can be made by glue oradhesive or other techniques.

The second corrugated structure 36 includes a plurality of openings orholes 42 to allow fluid flow therethrough.

As can be seen in FIG. 2, third sheet 30 is on an opposite side of thesecond sheet 16 as the first sheet 12. When the support structure 10 isconstructed as shown in FIGS. 1 and 2, the holes 14, 18, 32, and 42 willallow the passage of fluid, such as air or liquid, therethrough. Theseholes can be any shape.

In preferred constructions, the first sheet 12, second sheet 16, thirdsheet 30, first brace construction 20, and second brace construction 34are non-metal. The non-metal material can include cellulose. Othernon-metal materials can be used. For example, the core construction 10can be made of plastic.

While the example embodiment shows the support structure 10 as havingfirst sheet 12, second sheet 16, third sheet 30, first braceconstruction 20, and second brace construction 34, other embodiments caninclude further more sheets and more brace constructions.

In FIG. 1, it can be seen that the overall shape of the supportstructure 10 that is illustrated is rectangular in perimeter. Of course,other shapes can be used.

In the example shown in FIG. 1, each of the first sheet 12, second sheet16, third sheet 30, first corrugated sheet 24 and second corrugatedsheet 36 have a same length and a same width. There can be variations.The thickness, in this example, would be the distance between the firstsheet 12 and third sheet 30.

The support structure 10 can be useful in any sized filter elementlonger than about 2 inches, and particular, benefits can be achieved inelements that are long, such as elements having a length of at least 50inches, including elements having a length of at least 80 inches, and insome instances, elements being at least 90 inches long. In mostembodiments, the length between the first end 44 and second end 46 willtypically match the length of the element, in order to support thepleats, and be at least 50 inches long, or at least 80 inches long, orat least 90 inches long. In most embodiments, the support structureextends along the length of the filter element at least 50%, at least75%, at least 85%, or at least 95%.

In an alternate embodiment, the filter element includes multiple shortersupport structures, that may be connected, or may be spaced apart. Themultiple shorter elements added together extend along the length of thefilter element at least 50%, at least 75%, at least 85%, or at least95%.

In the embodiment of FIGS. 4 and 9, the inner pleat tips 62 are intouching engagement against the support structure 10. For example, inFIG. 4, it can be seen how inner pleat tip 62 a touches the first sheet12, while inner pleat tip 62 b touches the third sheet 30.

In some optional embodiments, the inner pleat tips 62 can be adhered tothe first sheet 12 and third sheet 30.

The filter element 70 includes a first end cap 72.

At an opposite end of the element 70, there is a second end cap 74.

The first end cap 72 and second end cap 74 are secured to opposite endsof the filter media 50.

In the example arrangement shown, the first end cap 72 is an open endcap in communication with the interior volume 54.

In the example shown, the second end cap 74 can be either a closed endcap or an open end cap.

Many different arrangements are possible. In many implementations, thepleated media 50 will be secured to the first and second end caps 72, 74by, for example, molding the ends of the pleated media 50 within the endcaps 72, 74. In such examples, the first end cap 72 and second end cap74 are made from a non-metal, molded material. In some examples, thefirst and second end cap 72, 74, can be made of other types of material,and have the media 50 secured through the use of potting material, forexample.

The filter element 70 will typically have a seal structure or gasket toprovide an air tight seal between the element 70 and whatever structurethe element 70 is installed. Many different embodiments are possible.

In the example shown in FIGS. 6 and 7, the element 70 is sealed within acollar 78. The element 70 is removable from the collar 78, and a seal isformed between the collar 78 and the end cap 72 through conventionalways. The collar 78 can have a gasket 80 (FIG. 6) attached thereto.Fasteners 82, 83, can be seen passing through the collar 78. In thisway, the filter element 70 can be secured to, for example, a tubesheet,with the fasteners 82, 83 tightened against the tube sheet to squeezethe gasket 80 between the collar 78 and tubesheet to form a sealtherebetween. It should be understood that this is just one example, andthere are many different examples of possible sealing arrangements thatcan be used for the element 70.

In FIG. 7, it can be seen how the support structure 10 is operablyoriented in the open interior volume 54. In this example, the firstsheet 12 forms a first wall 86 of porous material. The first wall 86 isoriented against the filter media 50 in the interior volume 54. Forexample, the first wall 86 will be against the inner pleat tips 62 (FIG.4). The third sheet 30 forms a second wall 88 of porous material. Thesecond wall 88 is spaced from and opposing the first wall 86. Inexamples that only have first and second walls 86, 88, there will not beany further porous walls in between. The first wall 86 and second wall88 are secured together in opposing relation. The forces are equal andopposite on the first and second walls 86, 88.

In this example, the support structure 10 includes third wall 90. Thirdwall 90 is formed by the second sheet 16. The third wall 90 is between,and spaced from, the first wall 86 and second wall 88. The third wall 90is secured to the first wall 86 and second wall 88.

In the example shown, the first wall 86 is secured to and spaced fromthe third wall 90 by the first brace construction 20.

In the example shown, the third wall 90 is secured to and spaced fromthe second wall 88 by the second brace construction 34.

The support structure 10 will preferably extend the length of theelement 70 between the first end cap 72 and second end cap 74.

The support structure 10, in some embodiments, can be removably orientedwithin the interior volume 54. In preferred arrangements, the supportstructure 10 will be secured, and non-removably oriented within theinterior volume 54. In one example, the support structure 10 will besecured to the second end cap 74. For example, the second end 46(FIG. 1) of the support structure 10 can be embedded, or molded, withinthe material forming the second end cap 74.

Other ways of permanently securing the support structure 10 to thesecond end cap 74 can be used. For example, the inner pleats tips 62 a,62 b could be adhered to support structure 10, which will also preventpleat tip bunching.

The first end 44 of the support structure 10 can be either freelymounted in the filter element 70, or it may be secured around the edgesto the first end cap 72. For example, the support structure 10 can bemolded or otherwise permanently secured to the first end cap 72.

The filter element 70, in the embodiment shown, has its perimeter shapefilled with the support structure 10. This will help to support thepleats 58 from collapsing against each other in the interior volume 54.As should be appreciated from the above, in preferred embodiments, thefilter element 70 is free of an inner liner. It can also be free of anouter liner. In many implementations, the filter element 70 is metalfree.

In some applications, the filter element 70 has a length between thefirst end cap 72 and second end cap 74 of at least 2 inches, frequentlyat least 50 inches, and in some instances, at least 80 inches, and instill other instances, at least 90 inches. In filter element 70, havingan oval shape and a length of over 50 inches, the support structure 10can have advantages, in that it is able to hold the pleats 58 apartalong the entire length between the opposite end caps 70, 74. Thesupport structure 10 is able to keep the pleats 58 from collapsingtogether, without adding the heaviness or weight of metal. In preferredembodiments where the support structure 10 is made of cellulose, thesupport structure 10 is environmentally friendly and recyclable.

FIGS. 10-12 illustrate another embodiment of support structure 10. InFIG. 10, support structure 10 comprises a pleated construction 102. Thepleated construction 102 has at least a partial section with a pluralityof pleats 104.

The plurality of pleats 104 in the pleated construction 102 can beextending in a direction that is non-parallel relative to a direction ofpleats 58 in the pleated filter media 50. Preferably, the pleats 104extend in a direction non-parallel and angled relative to the directionof pleats 58 of the pleated filter media 50.

FIG. 10 shows an arrow at 106 which is parallel to the direction ofpleats 58 of the pleated filter media 50. The direction of pleats 104 ispreferably angled at a non-zero angle relative to the direction 106 ofthe pleats of the pleated filter media 50. In one or more embodiments,the angle can be at least 20 degrees; or at least 30 degrees; or atleast 45 degrees; or at least 70 degrees. In one or more embodiments,the direction of pleats 104 can be at an angle 80-100 degrees relativeto the direction 106 of the pleats of the pleated filter media 50. Inthe example shown in FIG. 10, the pleated construction 102 has pleats104 extending in a direction about perpendicular relative to thedirection 106 of the pleats 58 of the pleated filter media 50. In one ormore embodiments, the angle can be 20-30 degrees; or 30-40 degrees; or45-70 degrees; or 70-80 degrees. In one or more embodiments, the anglecan be 20-100 degrees.

In FIG. 10, the pleats 104 extend from the first opposing interior face64 to the second opposing interior face 66 of the interior volume 54 ofthe pleated filter media 50. At least because the direction of pleats104 is angled relative to the direction of pleats 58, this providessupport to the pleated filter media 50.

The pleated construction 102 can be made from many types of materials.In preferred constructions, the pleated construction 102 comprises asemi-rigid pleated screen 110. The pleated screen 110 can be made fromplastic or a reinforced cellulose. The pleated screen 110 has an openscreen or mesh 112 to allow for fluid flow there through. Preferably,the pleated construction 110 has a void volume of no more than 60%.

FIG. 12 illustrates a top view of the filter element 70 with the supportstructure 10 in the form of pleated construction 102 operably assembledtherein.

The support structure 10, when operably oriented in the interior volume54, can act as a sound absorption mechanism. In noisy environments, suchas environments using compressors, this sound absorption can be helpfulin reducing the level of loudness and noise produced by the filterelement during operation. The support structure 10 may also perform verycoarse filtration.

FIGS. 13-18 illustrate another embodiment of support structure 10. InFIGS. 13-18, the support structure 10 comprises at least one moldedspacer 202. In preferred implementations, there are a plurality ofmolded spacers 202.

The molded spacers 202 have a longitudinal axis 204 (FIG. 18) extendinga length of the spacer 202 along its greatest dimension. Thelongitudinal axis 204 preferably extends in a direction that isnon-parallel to a direction of pleats 58 in the pleated media 50.

FIG. 13 shows an arrow at 206 which is parallel to the direction ofpleats 58 of the pleated media 50. The direction of the axis 204 of thespacer 202 is angled at a non-zero angle relative to the direction 206of the pleats of the pleated media 50.

In one or more embodiments, the angle of the spacer 202 relative to thedirection of pleats 58 of the pleated media can be at least 30 degreesand not greater than 170 degrees; or at least 45 degrees; or at least 70degrees. In one or more embodiments, the angle can be 30-150 degrees; or100-140 degrees.

In FIGS. 13-15, there are 4 spacers 202 depicted in the interior volume54 of the pleated media 50. At least two of the spacers 202 have adifferent length. For example, in FIGS. 13 and 14, two spacers 208, 209are oriented in the interior volume 54 adjacent to the curved endsections 211, 212 of the tubular construction of pleated media 50. Thesespacers 208, 209 are shorter in length than spacers 214, 215 orientedbetween the spacers 208, 209.

FIGS. 17 and 18 depict an example embodiment of one of the spacers 202.The spacer 202 has a first wall 218 and an opposite second wall 220.When oriented in the filter interior volume 54, the first wall 218 willbe secured to the interior face 64 of the pleated media 50, while thesecond wall 220 will be secured to the opposing interior face 66 of thepleated media 50.

The first wall 218 of the spacer 202 is depicted as relatively flat orplanar. The second wall 220 is depicted as having a plurality of groovesor scallops 222 therein. The scallops 222 will help to hold the innerpleat tips 62.

Many different sizes can be made. In some example embodiments, thedimension between the first wall 218 and second wall 220 is at least 0.5inch. In other examples, the dimension between the first wall 218 andsecond wall 220 is at least 1 inch and not greater than 12 inches. Inother embodiments, the dimension between the first wall 218 and secondwall 220 is 1-6 inches.

The spacers 202 can be made from many different types of materials. Itis advantageous when the material is made from a liquid that cures intoa solid because of convenient manufacturing techniques that can be used.For example, the spacers 202 can be made from polyurethane. Thepolyurethane can be high density polyurethane or a foaming polyurethane.The liquid material could have thixotropic properties as well.

The liquid material to be molded into the spacers 202 could be dispensedin liquid form onto the pleated media 50. Alternatively, the pre-curedliquid material to be molded into the spacers 202 could be dispensedinto a mold on which the pleated media 50 would then be placed on top ofto form a bond between the media 50 and the curing liquid. When theliquid material cures, it is secured to the media 50 to form the bridgebetween the opposing interior face 64 and interior face 66.

FIG. 19 is a schematic, cross-sectional view of another embodiment. Aswith the previous embodiments, there is support structure 10 operablyoriented in interior volume 54 of a construction of pleated media 50. Inthis embodiment, the pleated media 50 is tubular in shape, but hasopposite media ends 250, 251 in which one of the media ends 250 islarger than the other media end 251.

In the embodiment of FIG. 19, with the media end 250 being larger orwider than media end 251, there results a larger opening 254 than theopening compared to, for example, the opening of the first end cap 72shown in FIG. 7. The FIG. 19 construction, of course, can beincorporated into a filter element having end caps of the type shown anddescribed above with respect to FIGS. 5-7, in which the opening 254 willfunction as a filtration outlet 256.

The opening 256 can have a width that is greater in dimension ascompared to the media end 251 that it at least one inch greater and notmore than 6 inches greater. In some implementations, the width of themedia end 250 as compared to the media end 251 is between 2-4 inchesgreater.

The media end 251 can be completely closed, and the overall pleatedmedia can be sloped toward itself as it extends from the outlet 256 atmedia end 250 to a closed end 258 at media end 251.

In some implementations, having the wide end outlet 256 leads toadvantages including less restriction and increased flow, as fluid flowsfrom outside of the media 50 into the interior volume 54 and then outthrough the outlet 256.

The support structure 10 in the FIG. 19 embodiment is similar to thesupport structure 10 in the embodiment of FIGS. 10-12. That is, in theFIG. 19 embodiment, the support structure 10 comprises a pleatedconstruction 260. Pleated construction 260 is similar to pleatedconstruction 102 with the exception of pleat depth of the pleatedconstruction 60.

The pleated construction 260 has opposite first end 262 and second end264. The pleats 266 of the pleated construction 260 decrease in pleatdepth as the pleated construction 260 extends from the first end 262 tothe second end 264.

In FIG. 19, the first end 262 of the pleated construction 260 is evenwith or immediately adjacent to the outlet 256, while the second end 264is adjacent to the closed end 258. The pleated construction 260 canextend the pleat length of the interior volume 54 between the outlet 256and closed end 258. In one or more other embodiments, the pleatedconstruction 260 will extend only partially within the interior volume54.

The pleated construction 260 can be designed in accordance with thedescription above with the respect to the embodiment of FIGS. 10-12,which description is incorporated herein by reference.

For all of the above described embodiments of the pleated media 50, itmay be beneficial in some cases to put a pleat spacing or immobilizationfeature onto the pleated media 50. This can be done, for example, withhot melt beads across the pleat tips, such as the outer pleat tips 60 orthe inner pleat tips 62.

In operation, fluid, such as air or liquid, to be filtered will flowthrough the pleated media 50 and into the interior volume 54. The fluidwill be able to pass through the support structure because of theporosity through the support structure 10. The filtered fluid will thenbe conveyed out of the filter element 70 through the opening in thefirst end cap 72.

While filtering the fluid, the filter media 50 is supported to preventthe filter media 50 from collapsing together. This is done by using thesupport structure 10 in the interior volume 54.

The above specification provides examples of principles of thisdisclosure. Many embodiments can be made.

What is claimed is:
 1. A filter element comprising: (a) a tubularconstruction of pleated filter media defining an interior volume; (b)first and second opposite end caps secured to opposite ends of thefilter media; and (c) a semi-rigid pleated screen supporting the pleatedfilter media and operably oriented in the interior volume, wherein thesemi-rigid pleated screen is oriented between and against opposing facesof the pleated filter media, wherein the semi-rigid pleated screen haspleats extending in a direction non-parallel and angled relative to adirection of pleats of the pleated filter media; and  wherein the filterelement is free of an inner liner.
 2. The filter element according toclaim 1 wherein the pleats of the semi-rigid pleated screen extends atan angle 80-100 degrees relative to the direction of pleats of thepleated filter media.
 3. The filter element according to claim 1 whereinthe semi-rigid pleated screen is non-metal.
 4. The filter elementaccording to claim 1 wherein the semi-rigid pleated screen extends acomplete length between the first and second end caps.
 5. The filterelement according to claim 1 wherein the semi-rigid pleated screenextends less than a complete length between the first and second endcaps.
 6. The filter element according to claim 1 wherein the first endcap is an open end cap in communication with the interior volume.
 7. Thefilter element according to claim 1 wherein the second end cap is aclosed end cap.
 8. The filter element according to claim 1 wherein thepleated filter media is non-round.
 9. The filter element according toclaim 1 wherein the pleated filter media is oval.
 10. A method offiltering comprising: (a) providing a filter element according to claim1; (b) directing fluid to flow through the pleated filter media and intothe interior volume; and (c) while the fluid is flowing through thepleated filter media, supporting the filter media to prevent the filtermedia from collapsing together by using the semi-rigid pleated screen.11. The filter element of claim 1 wherein the semi-rigid pleated screenhas opposite first and second ends, and the pleats of the semi-rigidpleated screen decrease in pleat depth as the semi-rigid pleated screenextends from the first end to the second end.
 12. The filter element ofclaim 11 wherein the construction of pleated filter media defining theinterior volume has opposite media ends, with one media end being largerthan the other media end.
 13. The filter element of claim 1 wherein thesemi-rigid pleated screen is secured to at least the second end cap. 14.The filter element of claim 1 wherein the semi-rigid pleated screen issecured to at least the pleated media.
 15. The filter element of claim 1wherein the semi-rigid pleated screen is secured to each of the firstend cap and second end cap.
 16. A filter element comprising: (a) atubular construction of pleated filter media defining an interiorvolume; (b) first and second opposite end caps secured to opposite endsof the filter media; and (c) a semi-rigid pleated screen supporting thepleated filter media and operably oriented in the interior volume,wherein the semi-rigid pleated screen is oriented between and againstopposing faces of the pleated filter media, wherein the semi-rigidpleated screen has pleats extending in a direction non-parallel andangled relative to a direction of pleats of the pleated filter media;and wherein the semi-rigid pleated screen extends less than a completelength between the first and second end caps.
 17. The filter elementaccording to claim 16 wherein the pleats of the semi-rigid pleatedscreen extends at an angle 80-100 degrees relative to the direction ofpleats of the pleated filter media.
 18. The filter element according toclaim 16 wherein the pleated filter media is non-round.
 19. A filterelement comprising: (a) a tubular construction of pleated filter mediadefining an interior volume; (b) first and second opposite end capssecured to opposite ends of the filter media; and (c) a semi-rigidpleated screen supporting the pleated filter media and operably orientedin the interior volume, wherein the semi-rigid pleated screen isoriented between and against opposing faces of the pleated filter media,wherein the semi-rigid pleated screen has pleats extending in adirection non-parallel and angled relative to a direction of pleats ofthe pleated filter media; and wherein the semi-rigid pleated screen hasopposite first and second ends, and the pleats of the semi-rigid pleatedscreen decrease in pleat depth as the semi-rigid pleated screen extendsfrom the first end to the second end.
 20. The filter element accordingto claim 19 wherein the pleated filter media is non-round.